Simulation of a production line system with machine breakdowns using network modeling

In a manufacturing system, several factors can affect the reliability of the system in producing expected output levels, including resource input rates, labor rate variability, product quality, and machine failures. Although all of these factors will be reflected in the modeling process presented in this paper, the primary focus will be on the effect of machine breakdowns on system output. Network modeling and simulation with Q-GERT is the vehicle of analysis that is employed. This technique will be demonstrated via a realistic case example encompassing a complex production system consisting of several assembly lines, each containing several machines. The statistical results of the simulation of the example system are presented and discussed. In addition, examples of how the simulation model can be used to test changes in machine repair times and breakdown rates will be presented.